Control System for a Rotating Machine

ABSTRACT

A system for controlling movement of a work implement of a machine between a dump location and a plurality of dig locations includes a rotatable implement system, and an implement system pose sensor. A controller is configured to store first dig signals from the implement system pose sensor indicative of a first dig location, store second dig signals from the implement system pose sensor indicative of a second dig location spaced from the first dig location and store a dump location. The controller is further configured to generate command signals to move the work implement from the first dig location to the dump location, generate command signals to dump a load of material carried by the work implement at the dump location, and generate command signals to move the work implement from the dump location to the second dig location.

TECHNICAL FIELD

This disclosure relates generally to controlling a machine and, moreparticularly, to a control system for controlling movement of a workimplement while performing rotational material moving operations.

BACKGROUND

Machines for moving material such as a rope shovels, mining shovels,excavators, and backhoes may be configured for rotational movement tomove material between locations at a work site. For example, machineswith such rotational capabilities may dig material at a first locationsuch as a dig site with a material engaging work implement and rotatethe work implement to a second location such as a dump site at which thework implement is dumped or unloaded.

The machines may operate in an autonomous or semi-autonomous manner toperform these tasks in response to commands generated as part of a workplan for the machines. The machines may receive instructions inaccordance with the work plan to perform operations at the work site,such as those related to mining, earthmoving, construction, and otherindustrial activities.

The process of digging material at the first location and dumpingmaterial at the second location may be repeated numerous times over thecourse of a desired time period. Control of such machines may be acomplex task requiring a significant amount of skill on the part of anoperator and may require the manipulation of multiple input devices. Asan example, it is typically desirable to move the work implement in aconsistent and controlled manner along the desired path between thefirst location and the second location.

U.S. Pat. No. 5,968,104 discloses a hydraulic excavator having an arealimiting excavation control system. The area limiting excavation controlsystem has a setting device permitting an operator to set an excavationarea at which an end of a bucket is allowed to move. The area limitingexcavation control system also includes angle sensors disposed at pivotpoints of a boom, an arm, and a bucket for detecting respectiverotational angles and velocities thereof, a tilt angle sensor fordetecting a tilt angle of the excavator's body in a fore/aft direction,and a pressure sensor for detecting a load pressure of the boom as it ismoved upward in response to signals generated by a control lever.

The foregoing background discussion is intended solely to aid thereader. It is not intended to limit the innovations described herein,nor to limit or expand the prior art discussed. Thus, the foregoingdiscussion should not be taken to indicate that any particular elementof a prior system is unsuitable for use with the innovations describedherein, nor is it intended to indicate that any element is essential inimplementing the innovations described herein. The implementations andapplication of the innovations described herein are defined by theappended claims.

SUMMARY

In one aspect, a system for controlling movement of a work implement ofa machine between a dump location and a plurality of dig locationsincludes a rotatable implement system at a work site having a linkageassembly and the work implement, and an implement system pose sensor forgenerating implement system pose signals indicative of a pose of theimplement system including a pose of the work implement. A controller isconfigured to store first dig signals from the implement system posesensor indicative of a first dig location, store second dig signals fromthe implement system pose sensor indicative of a second dig locationspaced from the first dig location and store a dump location. Thecontroller is further configured to generate command signals to move thework implement from the first dig location to the dump location,generate command signals to dump a load of material carried by the workimplement at the dump location, and generate command signals to move thework implement from the dump location to the second dig location.

In another aspect, a controller implemented method for controllingmovement of a work implement of a machine between a dump location and aplurality of dig locations includes storing first dig signals from animplement system pose sensor associated with implement system theindicative of a first dig location, storing second dig signals from theimplement system pose sensor indicative of a second dig location spacedfrom the first dig location, and storing a dump location. The methodfurther includes generating command signals to move the work implementfrom the first dig location to the dump location, generating commandsignals to dump a load of material carried by the work implement at thedump location, and generating command signals to move the work implementfrom the dump location to the second dig location.

In still another aspect, a machine includes a rotatable base, a linkageassembly including a boom operatively connected to the rotatable base, aconnecting member operatively connected to the boom, and a materialmoving work implement operatively connected to the connecting member,and an implement system pose sensor for generating implement system posesignals indicative of a pose of the implement system including a pose ofthe work implement. A dump body has a lower surface defining an initialbed height onto which material is dumped from the work implement and abed height sensor generates bed height signals indicative of a bedheight of the dump body. A controller is configured to store first digsignals from the implement system pose sensor indicative of a first diglocation, store second dig signals from the implement system pose sensorindicative of a second dig location spaced from the first dig locationand store a dump location. The controller is further configured togenerate command signals to move the work implement from the first diglocation to the dump location, generate command signals to dump a loadof material carried by the work implement at the dump location, andgenerate command signals to move the work implement from the dumplocation to the second dig location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic view of a work site at which a machineincorporating the principles disclosed herein may be used;

FIG. 2 depicts a diagrammatic illustration of a machine in accordancewith the disclosure;

FIG. 3 depicts a diagrammatic illustration of a portion of the machineof FIG. 2 dumping a load of material into a haul truck;

FIG. 4 depicts a schematic view of a portion of the work site of FIG. 1;

FIG. 5 depicts an exemplary graph of the portion of the work site ofFIG. 4 plotting the radius as a function of angle in cylindricalcoordinates;

FIG. 6 depicts an exemplary graph similar to FIG. 5 but plotting theelevation as a function of angle in cylindrical coordinates;

FIG. 7 depicts a diagrammatic illustration of a haul truck;

FIG. 8 depicts an exemplary graph similar to FIG. 5 but furtherdepicting a stopping zone for the work implement and auto-lift zones forcertain obstacles;

FIG. 9 depicts an exemplary graph similar to FIG. 8 but plotting theelevation is a function of angle in cylindrical coordinates;

FIG. 10 depicts a schematic view similar to FIG. 4 but utilizing a 2ndhaul truck;

FIG. 11 depicts a schematic view similar to FIG. 4 but utilizing a 2nddig location;

FIG. 12 depicts a diagrammatic illustration of an excavator and a haultruck in accordance with the disclosure;

FIG. 13 depicts a flowchart illustrating a material moving process inaccordance with the disclosure; and

FIG. 14 depicts a flowchart illustrating a further aspect of thematerial moving process of FIG. 13.

DETAILED DESCRIPTION

FIG. 1 depicts a diagrammatic illustration of a work site 100 at whichone or more machines 10 may operate. Work site 100 may be a portion of amining site, a landfill, a quarry, a construction site, a roadwork site,a forest, a farm, or any other area in which movement of machines isdesired. As depicted, work site 100 includes an open-cast or open pitmine 101 having a face 102 from which material may be excavated orremoved by a machine 10 such as a rope shovel 15 and loaded into amachine such as a haul truck 80. The haul trucks 80 are depicted astraveling along a road 103 to dump location at which the material isdumped. Machines 10 such as dozers 95 may move material along a groundsurface 104 near the rope shovel 15 as well as near or towards a crestsuch as an edge of a ridge 105, embankment, high wall or other change inelevation. Face 102 and ground surface 104 may be collectively referredto herein as a work surface.

Referring to FIG. 2, an exemplary rope shovel 15 is depicted. Ropeshovel 15 includes a platform or base 16 rotatably mounted on anundercarriage or crawler 17. The crawler 17 may include a groundengaging propulsion device such as a pair of tracks 18 that operate topropel and turn the rope shovel 15. Base 16 may include a power unit,indicated generally at 19 and an operator station 20. The power unit 19provides or distributes electric and/or hydraulic power to variouscomponents of the rope shovel 15. A swing motor, indicated generally at21, is operative to control the rotation of the base 16 relative to thecrawler 17 about axis 22.

A linkage assembly or implement system may be mounted on the base 16 andincludes a boom 25 having a lower or first end 26 operative connected,such as by being fixedly mounted, to the base 16. An A-frame 28 may bemounted on the based 16 and one or more support cables 29 may extendbetween the A-frame and an upper or second end 27 of the boom 25 tosupport the second end of the boom. A pair of spaced apart sheaves 30may be mounted on the second end 27 of the boom 25.

The linkage assembly may further include a material engaging workimplement such as a bucket or dipper 35 fixedly mounted to a connectingmember or dipper handle 40. Dipper 35 may include a plurality ofmaterial engaging teeth 36 and a pivotable door 37 opposite the teeth topermit dumping or emptying of the dipper 35. At a first closed position,the door 37 retains material in the dipper 35 and at a second openposition (FIG. 3), material may exit the dipper through the door.

A hoist cable 45 extends from a hoist drum 46 on base 16, is supportedby sheaves 30 on the second end 27 of boom 25, and engages a bail orpadlock 38 associated with the dipper 35. Extension or retraction of thehoist cable 45 through rotation of a hoist motor, indicated generally at47, lowers or raises the height (i.e., the hoist) of the dipper 35relative to a ground reference. Material within the dipper 35 may bereleased by opening the door 37 of the dipper through the use of anactuator cable 48 that extends between the door and an door actuatormotor 49 on the base 16.

Dipper handle 40 is generally elongated and is operatively connected tothe boom 25. More specifically, the dipper handle 40 is slidablysupported within saddle block 41 and the saddle block is pivotablymounted on the boom 25. Extension or retraction (also referred to as“crowd”) of the dipper handle 40 may be controlled by a crowd controlmechanism operatively connected to the dipper handle and the saddleblock 41. In one embodiment, the crowd control mechanism may include adouble acting hydraulic cylinder 42 with one side of the hydrauliccylinder operatively connected to the dipper handle 40 and the otherside operatively connected to the saddle block 41. The crowd of thedipper handle 40 may thus be controlled by the operation of thehydraulic cylinder 42. In a second embodiment (not shown), a crowd ropeand a retract rope may be operatively connected to the dipper handle androuted around a crowd drum. Rotation of the crowd drum controls thecrowd of the dipper handle 40. In a third embodiment (not shown), a rackmay be mounted on dipper handle and a drive pinion mounted on the saddleblock. In the second embodiment, the crowd of the dipper handle 40 maybe controlled by operation of the pinion.

Rope shovel 15 may include an operator station 20 that an operator mayphysically occupy and provide input to control the machine. The operatorstation 20 may include one or more input devices (not shown) that anoperator may utilize to provide input to a control system, indicatedgenerally at 55, to control aspects of the operation of the rope shovel15. The operator station 20 may also include a plurality of displaydevices (not shown) to provide information to an operator regarding thestatus of the rope shovel 15 and material moving operations.

Control system 55 may include an electronic control module or controller56 and a plurality of sensors. The controller 56 may receive inputsignals from an operator operating the rope shovel 15 from withinoperator station 20 or off-board the machine through a wirelesscommunications system 110 (FIG. 1). The controller 56 may control theoperation of various aspects of the rope shovel 15 including positioningthe dipper 35 and opening the door 37 of the dipper to dump a load ofmaterial.

The controller 56 may be an electronic controller that operates in alogical fashion to perform operations, execute control algorithms, storeand retrieve data and other desired operations. The controller 56 mayinclude or access memory, secondary storage devices, processors, and anyother components for running an application. The memory and secondarystorage devices may be in the form of read-only memory (ROM) or randomaccess memory (RAM) or integrated circuitry that is accessible by thecontroller. Various other circuits may be associated with the controller56 such as power supply circuitry, signal conditioning circuitry, drivercircuitry, and other types of circuitry.

The controller 56 may be a single controller or may include more thanone controller disposed to control various functions and/or features ofthe rope shovel 15. The term “controller” is meant to be used in itsbroadest sense to include one or more controllers and/or microprocessorsthat may be associated with the rope shovel 15 and that may cooperate incontrolling various functions and operations of the machine. Thefunctionality of the controller 56 may be implemented in hardware and/orsoftware without regard to the functionality. The controller 56 may relyon one or more data maps relating to the operating conditions and theoperating environment of the rope shovel 15 and the work site 100 thatmay be stored in the memory of controller. Each of these data maps mayinclude a collection of data in the form of tables, graphs, and/orequations.

The control system 55 and the controller 56 may be located on the ropeshovel 15 and may also include components located remotely from themachine such as at a command center 111 (FIG. 1). The functionality ofcontrol system 55 may be distributed so that certain functions areperformed at rope shovel 15 and other functions are performed remotely.In such case, the control system 55 may utilize a communications systemsuch as wireless communications system 110 for transmitting signalsbetween the rope shovel 15 and a system located remote from the machine.

Rope shovel 15 may be equipped or associated with a plurality of sensorsthat provide data indicative (directly or indirectly) of variousoperating parameters of the machine. The term “sensor” is meant to beused in its broadest sense to include one or more sensors and relatedcomponents that may be associated with the rope shovel 15 and that maycooperate to sense various functions, operations, and operatingcharacteristics of the machine.

A pose sensing system 60, as shown generally by an arrow in FIG. 2, mayinclude a pose sensor 61 to sense the position and orientation (i.e.,the heading, pitch, roll or tilt, and yaw) of the rope shovel 15relative to the work site 100. The position and orientation of the ropeshovel 15 are sometimes collectively referred to as the pose of themachine.

The pose sensor 61 may include a plurality of individual sensors thatcooperate to generate and provide pose signals to controller 56indicative of the position and orientation of the rope shovel 15. In oneexample, the pose sensor 61 may include one or more sensors thatinteract with a positioning system such as a global navigation satellitesystem or a global positioning system to operate as a pose sensor. Inanother example, the pose sensor 61 may further include a slope orinclination sensor such as pitch angle sensor for measuring the slope orinclination of the rope shovel 15 relative to a ground or earthreference. The controller 56 may use pose signals from the pose sensors61 to determine the pose of the rope shovel 15 within work site 100. Inother examples, the pose sensor 61 may include a perception basedsystem, or may use other systems such as lasers, sonar, or radar todetermine all or some aspects of the pose of rope shovel 15.

If desired, the pose sensing system 60 may include distinct position andorientation sensing systems. In other words, a position sensing system(not shown) may be provided for determining the position of the ropeshovel 15 and a separate orientation sensing system (not shown) may beprovided for determining the orientation of the machine.

One or more implement sensors may be provided to monitor the positionand status of the dipper 35. More specifically, sensors may be providedto provide signals indicative of the position and other characteristicsof the dipper 35. A swing sensor 62 may be provided that generates swingsignals indicative of the angle of the base 16 relative to the crawler17. In one example, the pose sensing system 60 may determine the pose ofthe base 16 and the swing sensor 62 may determine the angle of thecrawler 17 relative to the base.

A hoist sensor 63 may be provided that generates hoist signalsindicative of the height of the dipper 35 relative to the base 16. Thehoist signals may be based upon the position of the hoist cable 45, thehoist drum 46, and/or the hoist motor 47. A door sensor 64 may beprovided that generates door signals indicative of the status (i.e.,open or closed) of the door 37 of the dipper 35. A crowd sensor 65 maybe associated with the boom 25, dipper handle 40, and/or saddle block41. The crowd sensor 65 may be configured to generate crowd signalsindicative of the crowd or position (i.e., the extension or retraction)of the dipper handle 40 relative to the boom 25.

Each of the sensors may embody any desired structure or mechanism. Whiledescribed in the context of position sensors that may be used todetermine the relative positions of the base 16, crawler 17, dipper 35,and dipper handle 40, some or all of the sensors may use another frameof reference such as a global navigation satellite system or a globalpositioning system. For example, one or more sensors may be similar tothe pose sensor 61 and determine positions relative to an earth oranother non-machine based reference.

Additional sensors may be provided on the rope shovel 15 including aweight or load sensor indicated generally at 66 for determining theweight or load of material within the dipper 35, one or more inertialmeasurement units or acceleration sensors indicated generally at 67 fordetermining a rate of acceleration of various components of the ropeshovel, and one or more inclination or pitch sensors 68 for determiningthe pitch of various components of the machine. In addition todetermining information regarding the rope shovel 15 directly (e.g., byusing acceleration sensor 67 to determine acceleration or using a pitchsensor 68 to determine pitch), the sensors may be used to determineadditional information regarding the performance of the machineindirectly (e.g., by using the acceleration sensor to determine velocityor the pitch sensor to determine pitch rate).

The positions of the components of the rope shovel 15 including base 16,boom 25, dipper 35 and dipper handle 40 may be determined based upon thekinematic model of the rope shovel together with the dimensions of thebase 16, crawler 17, dipper 35, and dipper handle 40, as well as therelative positions between the various components. More specifically,the controller 56 may include a data map that identifies the position ofeach component of the rope shovel 15 based upon the relative positionsbetween the various components. The controller 56 may use the dimensionsand the positions of the various components to generate and storetherein a three-dimensional electronic map of the rope shovel 15 at thework site 100. In addition, by knowing the speed or acceleration ofcertain components, the speed or acceleration of other components of therope shovel 15 may be determined.

The control system 55 may also include a terrain mapping system 70positioned on or associated with rope shovel 15 to scan work site 100and map the work surface surrounding the rope shovel as well as anyobstacles at the work site. The terrain mapping system 70 may includeone or more perception or perception sensors 71 (FIG. 4) that may scanwork site 100 to gather information defining the work surface thereof.More specifically, perception sensors 71 may determine the distance anddirection from the perception sensors 71 to points that define a mappedsurface such as the work surface as well as obstacles at the work site100. The field of view of each perception sensor 71 is depictedschematically at 72.

The obstacles may embody any type of object including those that arefixed or stationary as well as those that are movable or that aremoving. Examples of fixed obstacles may include infrastructure, storage,and processing facilities, buildings, trees, and other structures andfixtures found at a work site 100. Examples of movable obstacles mayinclude machines such as haul trucks 80, light duty vehicles (such aspick-up trucks and cars), personnel, and other items that may move aboutwork site 100.

Mapping or perception sensors 71 may be mounted on rope shovel 15 suchas at four corners of the machine as depicted in FIG. 4. In otherexamples, perception sensors 71 may be mounted at other locations on therope shovel 15, on other machines, or mounted in fixed locations at thework site 100. Perception sensors 71 may embody LIDAR (light detectionand ranging) devices (e.g., a laser scanner), RADAR (radio detection andranging) devices, SONAR (sound navigation and ranging) devices, cameras,and/or other types of devices that may determine the range and directionto objects and/or attributes thereof. Perception sensors 71 may be usedto sense the range, the direction, the color, and/or other informationor attributes about detected objects and the work surface and generatemapping signals indicative of such sensed information and attributes.

An object identification system, shown generally at 73, may be mountedon or associated with the rope shovel 15 in addition to the terrainmapping system 70. In some instances, the terrain mapping system 70 andthe object identification system 73 may be integrated together. Objectidentification sensors 74 may generate data that is received by thecontroller 56 and used by the controller to determine the type ofobstacles detected by the object identification system 73. The objectidentification sensors 74 may be part of the perception sensors 71 andthus are depicted schematically as the same components in FIG. 4. In analternate embodiment, the object identification sensors may be separatecomponents from the perception sensors 71.

The sensed data generated by the perception sensors 71 may be used bythe terrain mapping system 70 to generate an electronicthree-dimensional terrain map of the work site 100. The terrain map maybe overlaid or stored as a three-dimensional electronic map of the worksite 100 and include the three-dimensional map of the rope shovel 15. Inone example, the electronic map may be stored within controller 56and/or an offboard controller.

The data or data points defining the electronic map of the work site 100may be generated by the terrain mapping system 70 of rope shovel 15, byone or more machines having a terrain mapping system, or by acombination of the rope shovel and other machines. Regardless of themanner in which the electronic map is initially generated, datacollected by the terrain mapping system 70 of the rope shovel 15 and/orother machines having terrain mapping systems may be subsequently usedto update the electronic map.

Other or additional systems may be used to identify the position orlocation of obstacles at the work site 100 and generate data to bestored within the electronic map of the work site 100. In one example,machines at the work site 100 may each include a pose sensing systemsimilar or identical to the pose sensing system 60 of rope shovel 15.For example, a plurality of haul trucks 80 may be operating at work site100.

An example of a haul truck 80 is depicted in FIG. 7. Haul truck 80 mayinclude a frame 81 supported by one or more traction devices 82 and apropulsion system for propelling the traction devices. The propulsionsystem may include a prime mover, as shown generally at 83, and atransmission (not shown) operatively connected to the prime mover. Haultruck 80 may include a pivotable dump body 84 into which material may beloaded and from which material may be subsequently dumped. Referring toFIG. 4, dump body includes a front wall 85, a rear wall 86, a lowersurface 87, and a pair of opposite sidewalls 88 that extend between andconnect the front and rear walls. A cab or operator station 89 may beincluded that an operator may physically occupy and provide input tooperate the haul truck 80.

As with rope shovel 15, haul truck 80 may include a control system 90and a controller 91 similar to those of rope shovel 15 and thedescriptions thereof are not repeated. Haul truck 80 may include varioussystems and sensors for efficient operation of the machine such as apose sensing system 92 generally similar to that of rope shovel 15 and aload sensing system generally indicated at 93 to sense the load oramount of material within the dump body 84.

The pose sensing system 92 of haul truck 80 may operate in a mannersimilar to pose sensing system 60 of rope shovel 15. The pose of thehaul truck 80 may be communicated directly to the rope shovel 15 or to aremote system and the information entered or stored within theelectronic map of the work site 100. Dimensions of the haul truck 80 maybe determined or communicated and an electronic model of the truck maybe added to the electronic map. In one embodiment, identifyinginformation such as a code may also be transmitted from the haul truck80 with the pose information.

A data map within controller 56, either at rope shovel 15 or at a remotelocation, may utilize the identifying code to determine the dimensionsof the haul truck 80 and generate an electronic model of the haul truckbased upon the pose of the truck and its dimensions. In anotherembodiment, the identifying information that accompanies the poseinformation may also include the dimensions of the truck. In stillanother embodiment, the dimensions of each type of machine that may beoperating at the work site 100 may be stored within controller 56. Forexample, a list of potential haul trucks 80 that may be operating at thework site 100 together with their dimensions may be stored withincontroller 56. Upon determining that an obstacle is within apredetermined distance or proximity of the rope shovel 15, the objectidentification system 73 may identify the type of haul truck and utilizeits stored dimensions to generate an electronic model that is storedwithin the electronic map.

The electronic map may be configured in any desired manner. In oneexample, the electronic map may be configured to store the data in acylindrical coordinate system with the central axis of the cylindricalcoordinate system corresponding to the axis 22 of the rope shovel 15.For example, referring to FIG. 4, a portion of work site 100 is depictedwith rope shovel 15, haul truck 80, and dozer 95 adjacent a face 102 ofthe open pit mine 101. In FIGS. 5-6, the rope shovel 15, haul truck 80,dozer 95, and face 102 of FIG. 4 are depicted in a cylindricalcoordinate system about axis 22 with the y-axis of FIG. 5 depicting theradius from the axis 22 and the y-axis of FIG. 6 depicting the elevationrelative to a ground surface 104. In both instances, the x-axis depictsthe position or angle about axis 22 and a horizontal position oppositethe dipper 35 corresponding to both zero and 360 degrees.

Comparing FIG. 4 to FIGS. 5-6, one-to-one correspondence between many ofthe components, elements, or features of FIG. 4 may be found. Forexample, face 102 of the mine 101 is depicted in both FIGS. 5-6 andground surface 104 is depicted as being slightly above the x-axis inboth FIGS. 5-6 for clarity. The outer limit 120 of the reach of dipper35 is depicted in FIGS. 4-5 but not in FIG. 6.

Dipper 35 is spaced from the axis 22 and thus is depicted above thex-axis in FIG. 5. Although not visible in FIG. 4, the dipper 35 iselevated above the ground surface 104 and thus is depicted in FIG. 6above the ground surface.

Various obstacles adjacent the rope shovel 15 are also depicted in FIGS.5-6. Portions of the base 16 may contact obstacles adjacent the ropeshovel 15 while the rope shovel is rotating about axis 22. In addition,in some instances, it may be possible for the dipper 35 to contact thebase 16. Accordingly, a keep-out zone 121 corresponding to an outer pathof travel of the base 16 relative to axis 22 is depicted in FIGS. 4-5.The keep-out zone 121 is not depicted in FIG. 6. The tracks 18 may alsobe obstacles since it is possible for the dipper 35 to contact themunder certain circumstances. The tracks 18 are depicted in FIGS. 4-5 butnot in FIG. 6.

Haul truck 80 includes portions that are obstacles and also a portionthat is a target zone for the dipper 35. More specifically, the forwardportion of the haul truck 80, including the operator station 89, isdepicted at 122. The rearward portion 123 of the haul truck may bedivided into two sections with the dump body 84 depicted as the targetzone 124 and the remainder as an obstacle 125. More specifically, thedump body 84 may be seen in FIGS. 4-6 as being defined by front wall 85,rear wall 86, lower surface 87, and sidewalls 88. As best seen in FIG.5, the cylindrical coordinate boundaries of the target zone 124 aredefined in one direction by sidewalls 88 that define the radialboundary, and in a perpendicular direction by the front wall 85 and rearwall 86 that define the circumferential boundary. The elevationcomponent of the target zone 124 is defined by the lower surface 87 ofthe dump body 84 as well as the upper surfaces of the each of the frontwall, 85, rear wall 86, and sidewalls 88.

Dozer 95 is depicted in FIG. 5 as an obstacle spaced from the axis 22and has a height beginning at ground surface 104.

Rope shovel 15 may be configured to be operated autonomously,semi-autonomously, or manually. When operating semi-autonomously ormanually, rope shovel 15 may be operated by remote control and/or by anoperator physically located within the operator station 20. As usedherein, a machine operating in an autonomous manner operatesautomatically based upon information received from various sensorswithout the need for human operator input. As an example, a haul truckthat automatically follows a path from one location to another and dumpsa load at an end point may be operating autonomously. A machineoperating semi-autonomously includes an operator, either within themachine or remotely, who performs some tasks or provides some input andother tasks are performed automatically and may be based uponinformation received from various sensors. As an example, a haul truckthat automatically follows a path from one location to another butrelies upon an operator command to dump a load may be operatingsemi-autonomously. In another example of a semi-autonomous operation, anoperator may dump a dipper or bucket of a rope shovel 15 or an excavator200 (FIG. 12) into a haul truck 80 and a controller 56 may automaticallyreturn the dipper or bucket to a position to perform another diggingoperation. A machine being operated manually is one in which an operatoris controlling all or essentially all of the functions of the machine. Amachine may be operated remotely by an operator (i.e., remote control)in either a manual or semi-autonomous manner.

Control system 55 may include a module or planning system, indicatedgenerally at 75 in FIG. 2, for determining or planning various aspectsof a material moving operation. The planning system 75 may utilizevarious types of inputs from the sensors associated with the rope shovel15 as well as the electronic map of the work site 100 including theconfiguration of the work surface, the position of the rope shovel, theposition and movement of any obstacles adjacent the rope shovel, desiredor proposed dig location(s), desired or proposed dump locations(s), andthe characteristics of the material to be moved. Capabilities anddesired operating characteristics and capabilities of the rope shovel 15as well as its kinematic model may also be stored within controller 56and used by the planning system 75. The planning system 75 may simulateand evaluate any aspect of a material moving operation, such as byevaluating a plurality of potential paths between the current locationof the dipper 35 and a target zone, and then select (or provide feedbackregarding) a proposed dig location, dump location, and/or the pathbetween the dig location and the dump location that creates the mostdesirable results based upon one or more criteria.

One example of a desired operating characteristic, the controller 56 maybe configured to minimize changes in direction such as only moving eachof the swing, crowd, and hoist of the linkage assembly in a singledirection during a material moving cycle or operation. In anotherexample of a desired operating characteristic, the planning system 75may be configured to avoid passing over any obstacles at the work site,if possible. In other words, while swinging the base 16 and the linkageassembly, the planning system 75 may move the dipper 35 and dipperhandle 40 to a desired hoist and crowd, respectively, and continued toswing the dipper over the dump body 84 while generally maintaining thehoist until opening the door 37 of the dipper during the dumpingprocess.

The planning system 75 may be utilized regardless of whether the ropeshovel 15 is being operated autonomously, semi-autonomously, ormanually. When operating the rope shovel 15 manually, the planningsystem 75 may provide suggestions for dig locations, dump locations, andpaths therebetween. When operating autonomously or semi-autonomously,the planning system 75 may determine, and the controller 56 maygenerate, commands to direct the dipper 35 to the desired location or ina desired manner such as by controlling the rotation of the base 16relative to the crawler 17, the movement of the dipper handle 40relative to the boom 25, and the height of the dipper 35. Such commandsmay control both the speed and acceleration (and deceleration) of eachtype of movement of the rope shovel 15 (i.e., rotation, crowd, andhoist).

In view of the size of the rope shovel 15 and the large payloads thatmay be carried within the dipper 35, it may be difficult or evenimpossible to stop the rope shovel quickly. For example, rope shovel 15may be a massive machine with a dipper 35 capable of carrying a payloadof greater than 100 tons of material. Accordingly, the planning system75 may generate a stopping zone 126 (FIGS. 5-6) within the electronicmap through which components of the rope shovel 15 may travel bypredicting the path or motion of the rope shovel based upon its speed,acceleration, and mass (including a payload) in the absence ofadditional inputs. In other words, the stopping zone 126 may identify ananticipated path of the machine based upon the machine's momentum.

The planning system 75 may also generate auto-lift zones within theelectronic map adjacent obstacles to provide an additional safetyfactor. More specifically, an auto-lift zone may be defined adjacenteach obstacle so that if the dipper 35 or dipper handle 40 enters thezone, the controller 56 may automatically lift or raise the dipper in anattempt to raise the dipper over the obstacle rather than it continuinginto contact with the obstacle. The size of each auto-lift zone may be afunction of the obstacle, the payload within the dipper 35, and thevelocity of the dipper. Referring to FIGS. 8-9, a first radial auto-liftzone 130 is positioned on opposite sides of the dozer 95 and a firstelevation auto-lift zone 131 is positioned on opposite sides of thedozer.

If the dipper 35 approaches the dozer 95 from either direction as thedipper is being swung, it will approach the first radial auto-lift zone130 (FIG. 8) and the controller 56 may generate commands to cause thedipper to be raised. If the dipper 35 is higher than the first elevationauto-lift zone 131 (FIG. 9), the dipper may pass over the dozer 95without any action by the controller 56 or an operator. It should benoted that the elevation auto-lift zones are angled upward from theground surface 104 since the urgency of raising the dipper 35 may be afunction of the distance from the obstacle and the increase in elevationnecessary to avoid the obstacle.

A second radial auto-lift zone 132 is positioned on opposite sides ofthe haul truck 80. An opening 133 extends partially through the secondradial auto lift zone 132 in alignment with the dump body 84. A secondelevation auto-lift zone 134 is positioned on opposite sides of the haultruck 80 and is associated with one of the second radial auto-lift zones132 except along the opening 133. At the opening 133, a third elevationauto-lift zone 135 is positioned on the left side of the haul truck asviewed in FIGS. 8-9.

If the dipper 35 approaches the haul truck 80 from the right as viewedin FIGS. 8-9 as the dipper is being swung, it will approach the secondradial auto-lift zone 132 (FIG. 8) to the right of the haul truck andthe controller 56 may generate commands to cause the dipper to beraised. If the dipper 35 is higher than the second elevation auto-liftzone 134 (FIG. 9), the dipper may pass over the haul truck 80 withoutany action by the controller 56 or an operator.

If the dipper 35 approaches the haul truck 80 from the left as viewed inFIGS. 8-9 as the dipper is being swung and it is above the thirdelevation auto-lift zone 135 (FIG. 9) regardless of its radial position,the dipper may pass over the haul truck 80 without any action by thecontroller 56 or an operator. If the dipper 35 approaches the haul truck80 from the left and is aligned with either of the second radialauto-lift zones 132, the controller 56 may determine whether the dipperis above the third elevation auto-lift zone 135. If the dipper is notabove the third elevation auto-lift zone 135, the controller 56 maygenerate commands to cause the dipper to be raised.

If the dipper 35 approaches the haul truck 80 from the left and isaligned with the opening 133, the controller 56 may determine whetherthe dipper is above the fourth elevation auto-lift zone 136. If thedipper is not above the fourth elevation auto-lift zone 136, thecontroller 56 may generate commands to cause the dipper to be raised.

In order to improve the material moving process (regardless of whetherit is being performed autonomously, semi-autonomously, or manually), are-spotting or re-positioning system, indicated generally at 76 in FIG.2, may be provided to identify instances in which it is desirable tore-position a haul truck 80 prior to dumping a load of material. Forexample, it may be desirable for the dipper 35 to enter the space ortarget zone at the dump body 84 by moving over the rear wall 86 with thedipper at an angle and between the sidewalls 88 as depicted in phantomin FIG. 3. Still further, it may be desirable for a lower portion of thedipper 35 to travel or pass over the rear wall 86 but be positionedlower than an upper surface of the sidewalls 88 as depicted in FIG. 3.As such, the window or target into which it is desired to move thedipper 35 may be relatively small.

In some instances it may be desirable to generally center the dipper 35between the front wall 85 and rear wall 86 of the dump body but positionthe dipper closer to the sidewall closest to the rope shovel 15 asdepicted in FIGS. 10-11. Upon beginning the dumping process, thecontroller 56 may generate commands to pull the actuator cable 48 andalso extend or crowd out the dipper handle 40 to further increase theforce applied to the actuator cable. By positioning the dipper 35 closerto the sidewall 88 nearest the rope shovel 15, the dipper may be crowdedout without engaging the sidewall farthest from the rope shovel.

The re-positioning system 76 may be configured to analyze the pose of ahaul truck 80 and the pose and kinematic model or capabilities of therope shovel 15, as well as the location of any additional obstacles atthe work site 100, to determine whether the dipper 35 may be efficientlyand/or safely moved to the target zone at the dump body 84 and dumped orwhether it is desirable to re-position of the haul truck prior todumping. For example, the controller 56 may determine a plurality ofpaths that the dipper 35 may travel from its current location (asdetermined by the pose of the rope shovel 15) to the target zone at thedump body 84 based upon the kinematic model of the implement system andthe desired operating characteristics of the implement system.

In one example, the haul truck 80 may be too close to the base 16 ofrope shovel 15 (i.e., within keep-out zone 121) so that rotation of thebase during the loading process would cause a collision or the dipper 35cannot be maneuvered into the desired loading position generallycentered between the front wall 85 and rear wall 86 in a first directionand between the sidewalls 88 in a second direction, with the seconddirection being generally perpendicular to the first direction.

In another example, the haul truck 80 may be too far away from the ropeshovel 15 so that the dipper 35 may not be centered relative to the dumpbody 84 even if the dipper handle 40 is fully extended or crowded out(i.e., outside the outer limit 120 of the reach of the dipper). In stillanother example, the haul truck 80 may be positioned too far forward ortoo far rearward and at an angle such that the dipper 35 cannot enterthe target zone or space above the dump body 84 along the center of therear wall 86 (FIG. 3).

In a further example, the haul truck 80 may be positioned at a locationin which the dipper 35 may be positioned as desired above the dump body84 but the haul truck is positioned at a location relatively far fromthe dig location. In such case, it may be desirable to re-position thehaul truck 80 so that the time spent by the rope shovel 15 swingingbetween the dig and dump positions is reduced, thus increasing theefficiency of the material loading process.

If the re-positioning system 76 analyzes the pose of the haul truck 80and the pose and kinematic model of the rope shovel 15 (or the pose ofthe boom 25) and determines that it is desirable to re-position the haultruck 80, the operator of the haul truck may be instructed tore-position the haul truck at a new location or a new orientation.

In some instances, the re-positioning system 76 may be configured tooperate based upon the position or pose of any portion of the implementsystem together with the kinematic model of the implement system withoutthe pose of the entire rope shovel 15 or even the pose of the dipper 35.In doing so, the controller 56 may determine the position or pose of aportion of the implement system and determine all possible locations forthe dipper 35 based upon the position of the portion of the implementsystem. The controller 56 may then analyze potential paths of the dipper35 to the target zone based for each of the possible locations of thedipper 35 together with the kinematic model of the implement system andthe desired operating characteristics of the implement system. Forexample, if the position of the boom 25 is known, the controller 56 maydetermine all possible positions for the dipper 35 and the dipper handle40. The controller may then determine potential paths of the dipper 35to the target zone based upon each possible position of the dipper.

The instructions to re-position the haul truck 80 may take any desiredform. In one example, the instructions may be provided as an alertcommand between the controller 56 of rope shovel 15 and controller 91 ofhaul truck 80. The instructions may result in a written communication ona display within the haul truck 80, another type of visual indicationsuch as flashing certain lights of the haul truck, or an audiblecommunication or indication such as by generating a verbal request orsounding a horn or an alarm of the haul truck. In another example, therope shovel 15 may generate an alert commands as visual or audibleindications such as flashing lights or sounding an alarm on the ropeshovel.

When dumping or unloading a load of material from dipper 35, in someinstances, it may be desirable to position the dipper at a specified orpredetermined distance above the dump body 84 to reduce or minimize thedistance that material falls as it fills the dump body. By reducing orminimizing distance that the material falls, the impact of the materialon the haul truck 80 is reduced, which reduces wear on the haul truck 80and fatigue on the truck operator.

If the dipper 35 is positioned the predetermined distance above thelower surface 87 of the dump body 84 when the dump body is empty, as thedump body is filled with material, the dump height of the dipper must beincreased if it is desired to maintain the relative dump height (i.e.,the distance the material falls) to compensate for the additionalmaterial. In other words, if it is desirable to maintain a specifieddistance that the material falls into the dump body 84, the height ofthe dipper 35 during the dumping process must be sequentially increasedafter each dumping cycle due to the addition of material into the dumpbody.

Referring to the height of the surface upon which the material is beingdumped as the bed height, the lower surface 87 may define the initialbed height. As each load of material is added to the dump body 84, theadditional material changes the effective bed height (i.e., the heightof the upper surface upon which the next load may be dumped).Accordingly, to maintain the desired relative dump height, it may bedesirable to increase the absolute position of the dipper 35 relative tothe ground surface 104.

Control system 55 may include a dump height positioning system,indicated generally at 77 in FIG. 2, that operates to determine adesired height of the dipper 35 at which each dumping or unloadingoperation should occur. The dump height positioning system 77 maycontrol the dump height when performing material moving operationsautonomously or semi-autonomously and may be used to suggest a dumpheight when operating the rope shovel 15 manually.

In operation, the dump height positioning system 77 may first determinethe height of the lower surface 87 of the dump body 84 relative toground surface 104. In one example, the perception sensors 71 of theterrain mapping system 70 may be high enough to determine the height ofthe lower surface 87 relative to the ground surface 104 (i.e., the bedheight). In another example, the position of the lower surface 87 may bedetermined from the pose of the haul truck 80 together with knownmachine dimensions such as those associated with an identifying code forthe haul truck as discussed above.

After determining the height of the lower surface 87, the dipper 35 maybe moved to the desired position (i.e., at the desired height above thelower surface and generally centered relative to the dump body 84) andthe door 37 of the dipper opened to dump the material. The addition ofmaterial on top of the lower surface 87 of dump body 84 will likelyincrease the effective bed height. The dump height positioning system 77may determine or estimate a new effective bed height in any desiredmanner. In one example using a closed loop system, the perceptionsensors 71 may be utilized to determine the new effective bed height. Inanother example using a closed loop system, additional mapping orperception sensors, indicated generally at 79, may be provided at thedipper 35 or dipper handle 40 and operate in a manner similar to theperception sensors 71 to determine the effective bed height.

In an example using an open loop system, the dump height positioningsystem 77 may estimate the new effective bed height based upon thedimensions or capacity of the dipper 35 and the dimensions or capacityof the dump body 84 of haul truck 80. In a further example using an openloop system, the dump height positioning system 77 may estimate the neweffective bed height by raising the previous effective bed height by apredetermined increment or distance.

Upon determining or estimating a new effective bed height, a new dumpheight may be determined based upon the new effective bed height and therelative dump height. The dipper 35 may be moved to its desired positionabove the dump body 84 and the material dumped into the haul truck 80.The process of determining or estimating a new or subsequent effectivebed height, a new or subsequent dump height, and performing a materialmoving operation may be repeated until the haul truck 80 is filled tothe desired level.

It should be noted that in some instances, the dump height positioningsystem 77 may determine a new dump height by raising the previous dumpheight based upon the dimension of the dipper and the dimensions of thedump body 84 rather than estimating a new effective bed height byraising the previous effective bed height by a predetermined incrementand then calculating a new dump height.

In another example, the dump height positioning system 77 may operate bydetermining a first or initial dump height based upon the initial bedheight and increasing the dump height by a predetermined amount aftereach dump process until the dump body 84 is full. In one example, thepredetermined amount that the dump height is increased for eachsubsequent cycle may be generally identical. In another example, thepredetermined amount that the dump height is increased for eachsubsequent cycle may be different. In instances in which more than threedump cycles are used for a haul truck 80, the predetermined distancesmay be generally identical, different, or a combination.

Upon dumping each load of material, the rope shovel 15 may be operatedto return the dipper 35 to a desired dig location. This process may bereferred to as a return-to-dig process and may be performedautonomously, semi-autonomously, or manually. When operatingautonomously or semi-autonomously, a return-to-dig system, indicatedgenerally at 78 in FIG. 2, may be configured to move the dipper 35sequentially between one or more dig locations and one or more dumplocations. The dig locations may be set automatically, by an operator,or other personnel. In addition, the desired sequence may be setautomatically, by an operator, or other personnel.

In one example depicted in FIG. 10, a material moving operation may beconfigured with a single rope shovel 15 operating at a single diglocation 140 together with a first loading or dump location 141 and asecond loading or dump location 142 at which haul trucks 80 may beloaded. The first dump location 141 and the second dump location 142 maybe positioned at any location but are depicted in FIG. 10 on oppositesides of the rope shovel 15.

During a material loading operation, material may be loaded into thedipper 35 at the dig location 140 and the dipper moved into alignmentwith a first haul truck 80 located at the first dump location 141 andunloaded. Upon emptying the dipper 35, the controller 56 may generatecommand signals to move the dipper back to the dig location 140 and theprocess of loading the first haul truck 80 may be repeated until thefirst haul truck is fully loaded.

Either before or while the rope shovel 15 is loading the first haultruck 80, a second haul truck may be positioned at the second dumplocation 142. Once the first haul truck 80 is fully loaded, the firsthaul truck may depart the first dump location 141 and the dipper 35returned to the dig location 140 to begin another dipper loading andunloading cycle. After loading the dipper 35, the dipper may be movedinto alignment with the second haul truck 80 located at the second dumplocation 142 and unloaded. Upon emptying the dipper 35, the dipper maybe moved back to the dig location 140 and the process of loading thesecond haul truck 80 is repeated until the second haul truck is fullyloaded. Either before or while the rope shovel 15 is loading the secondhaul truck 80, an empty haul truck may be positioned at the first dumplocation 141 and the loading process may be repeated at the first dumplocation once the second haul truck is fully loaded. With theconfiguration depicted in FIG. 10, the rope shovel 15 may becontinuously operated by positioning an empty haul truck 80 at eitherthe first dump location 141 or the second dump location 142 while therope shovel is loading a haul truck at the other dump location.

In a second example depicted in FIG. 11, a material moving operation maybe configured with a rope shovel 15 digging at both a first dig location145 and a second dig location 146 and dumping at a single dump location147. The first dig location 145 may be located generally near oradjacent the dump location 147 and the second dig location 146 locatedfarther from the dump location.

During a material loading operation, material may be loaded into thedipper 35 at the first dig location 145 and the dipper moved intoalignment with a haul truck 80 located at the dump location 147 andunloaded. Upon emptying the dipper 35, the controller 56 may generatecommand signals to move the dipper back to the first dig location 145and the process of loading the haul truck 80 may be repeated until thehaul truck is fully loaded. Once the haul truck 80 is fully loaded, thehaul truck may depart the dump location 147 and an empty haul truckpositioned at the dump location.

While the loaded haul truck 80 is leaving the dump location 147 and theempty haul truck is being positioned at the dump location, the dipper 35may be moved to the second dig location 146 and material loaded into thedipper. The dipper 35 may be moved back to the dump location 142 to fillthe newly positioned empty haul truck 80. Upon emptying the dipper 35,the dipper may be moved to the first dig location 140 and the process ofdigging at the first dig location and loading the haul truck 80 at thedump location 147 may be repeated until the haul truck is fully loaded.With the configuration depicted in FIG. 11, the time required to movethe fully loaded haul truck 80 from the dump location 147 and positionan empty haul truck thereat may be utilized more efficiently bydirecting the rope shovel 15 to load the dipper 35 at the second diglocation 146, which is located farther from the dump location ascompared to the first dig location 145.

In a further example, a configuration may be utilized that is similar tothat of FIG. 11 but includes a second dump location, indicated generallyat 148, near the second dig location 146. By adding the second dumplocation 148, the rope shovel 15 may load a haul truck at each dumplocation and then dig material at a dig location near each dumplocation.

The positions of the dig locations may be set in any desired manner. Inone example, the dig locations may be set by an operator manually movingthe dipper to a desired location and actuating an input device such as aswitch (not shown) within the operator station 20. The signals from thesensors (e.g., swing sensor 62 and crowd sensor 65) indicative of thegeneral position of the desired dig location may be stored withincontroller 56 to subsequently identify the desired dig location. Theprocess may be repeated for each dig location.

In another example, the desired dig locations may be set or stored byentering the control system 55 into a learning mode and an operatoroperating the rope shovel 15 to perform a digging operation. Uponperforming the digging operation, the controller 56 may determine theswing position from swing sensor 62 and the crowd from crowd sensor 65and store the positions to subsequently identify the desired diglocation.

In still another example, the desired dig locations may be set or storedby identifying the locations on the electronic map stored withincontroller 56. More specifically, an operator may identify or inputdesired dig locations on a display device within the operator station20.

Referring to FIGS. 13-14, flowcharts of a semi-autonomous materialmoving operation using rope shovel 15 is depicted. The flowcharts depicta process in which an operator may manually perform a digging operationand the controller 56 of rope shovel 15 semi-autonomously moves thedipper 35 into alignment with a haul truck 80, dumps the load within thedipper, and returns the dipper to a dig location at which the operatormay perform a new digging operation. At stage 150, characteristics ofthe machines operating at the work site 100 may be entered intocontroller 56. The characteristics may include operating capacities,dimensions, desired operating characteristics, and other desired ornecessary information. Examples may include the kinematic model of therope shovel 15 and the dimensions of the haul trucks 80.

An electronic map of the work site 100 may be generated at stage 151. Inone example, the electronic map may be created by the terrain mappingsystem 70. The perception sensors 71 may generate mapping signals thatare received by controller 56 and the controller may convert the mappingsignals into an electronic map of the work site 100. The electronic mapmay include representations that depict the positions of face 102,ground surface 104, and the rope shovel 15. In addition, each of theobstacles located by the terrain mapping system 70 and/or identified bythe object identification system 73 may be included in the electronicmap.

While the electronic map may be generated and stored in a rectangular orCartesian coordinate system, it may be desirable to convert and/or storethe electronic map in a cylindrical coordinate system. Storing theelectronic map in a cylindrical coordinate system with the map centeredabout axis 22 may simplify the generation of command signals by thecontroller 56, the operation of the planning system 75, and thedetermination of whether a portion of the rope shovel 15 is likely tocome into contact with an obstacle.

At stage 152, the controller 56 may determine the position or pose ofthe target zone 124 including the height of the lower surface 87 of thedump body 84 relative to ground surface 104 and store the informationwithin the electronic map of the controller 56. The position or pose ofthe target zone may be determined based upon information from theterrain mapping system 70, the pose sensing system 92, other mapping orperception systems, information from a data map stored within anycontroller, and/or any other desired systems.

Auto-lift zones around each obstacle may also be determined and storedwithin the electronic map at stage 152.

One or more dig locations may be set or stored at stage 153 withincontroller 56. The dig locations may be identified and stored withincontroller 56 in any desired manner. In one example, an operator maymove the dipper 35 to a desired dig location and actuate an input devicesuch as a switch (not shown) within the operator station 20. Signalsfrom the sensors (e.g., swing sensor 62, hoist sensor 63, and crowdsensor 65) indicative of the position of the desired dig location may bestored within controller 56.

At stage 154, the dipper 35 may be loaded with material such as from theface 102 of the mine 101 (FIG. 1). It should be noted that the operationof stages 153 and 154 may be reversed or may occur simultaneouslydepending upon the manner in which the dig location(s) are stored. Theplanning system 75 may plan at stage 155 a desired path to the dumplocation. More specifically, the planning system 75 may determine thedesired path for the dipper to travel from to the target zone 124 at thedump body 84 of the haul truck 80. Upon initially loading the dipper 35,the planning system 75 may determine the desired path from the diglocation to the dump location. As the dipper 35 moves towards the dumplocation, the controller 56 may concurrently determine and update thedesired path of the dipper from its current location to the target zone124.

While determining the path of the dipper 35, the controller 56 may alsodetermine the stopping zone 126 of the dipper 35. Since the stoppingzone 126 is generally a function of the momentum of the rope shovel 15,the length of the stopping zone will typically increase as the ropeshovel moves more rapidly. It should be noted that by avoiding obstaclesthat are radially between the dipper 35 and the base 16, the likelihoodof contact between an obstacle and any portion of the rope shovel 15 isreduced.

The controller 56 may generate at stage 156 command signals to move thedipper 35 along the identified or predetermined path towards the targetzone 124. While moving the dipper 35, the controller 56 may receive atstage 157 data from the sensors associated with the rope shovel 15together with any sensors associated with the obstacles and the worksite 100 to update the electronic map of the work site. Based upon theposition, speed, and acceleration of the rope shovel 15 as well as theobstacles adjacent the rope shovel, the controller 56 may determine atdecision stage 158 whether the rope shovel is likely to make contactwith an obstacle as the dipper moved towards the target zone 124.

If the rope shovel 15 is likely to contact an obstacle, the controller56 may determine at decision stage 159 (FIG. 14) whether the obstacle ismoving. If the obstacle is moving, the controller 56 may pause or waitat stage 160 for a predetermined period of time in case the obstaclemoves sufficiently out of the path of the rope shovel 15. If theobstacle has moved sufficiently so that contact or a collision betweenthe rope shovel 15 and the obstacle may be avoided, movement of thedipper 35 may be continued by referring back to FIG. 13 at stage 155.

If the obstacle is not moving at decision stage 159 or has not moved outof the path within the predetermined time period at decision stage 161,controller 56 may determine at decision stage 162 whether movement ofthe rope shovel 15 may be stopped within a sufficient distance or timeperiod to avoid a collision with the obstacle. If the rope shovel 15 maybe stopped without a collision, the controller 56 may generate commandsto stop the machine at stage 163. If the rope shovel 15 may not bestopped without a collision, the controller 56 may generate commands atstage 164 to raise the dipper 35 in an attempt to pass over theobstacle.

If the rope shovel 15 is not going to contact an obstacle, thecontroller 56 may determine at decision stage 165 whether the dipper 35is sufficiently aligned with the target zone 124 including beingpositioned as desired at the dump body 84 and positioned at the desireddump height above the lower surface 87 of the dump body. If the dipper35 is not sufficiently aligned with the target zone 124 and at thedesired dump height, the dipper may continue to be moved towards thedesired position and stages 155-8, 165 repeated.

If the dipper 35 is aligned with the target zone 124 and at the desireddump height, the controller 56 may dump at stage 166 the load ofmaterial into the dump body 84. To do so, the controller 56 may generatea command to actuate the door actuator motor 49 which engages actuatorcable 48 to open the door 37.

At stage 167, the controller 56 may determine the new effective bedheight of the dump body 84. To do so, the controller 56 may utilizeperception sensors 71, additional sensors 79, an estimate of the changein bed height due to the addition of material into the dump body 84, orany other desired system or process. At stage 168, the controller 56 maygenerate commands to return the dipper 35 to a desired dig location andstages 154-168 repeated.

While the dipper 35 is being returned to the desired dig location, thecontroller 56 may determine at decision stage 169 whether the haul truck80 is fully loaded. In one embodiment, the controller 56 may make such adetermination based upon the analysis of the new effective bed height ofthe dump body 84. In another embodiment, a load sensing system 93 ofhaul truck 80 may be used to determine when the haul truck is fullyloaded. If the haul truck 80 is not fully loaded, the haul truck mayremain in place and the material moving process may be continued andstages 154-169 repeated.

If the haul truck 80 is fully loaded, the haul truck may be moved atstage 170 from the dump location and transported to a desired locationspaced from the dump location. Once the fully loaded haul truck 80 hasbeen moved from the dump location, an empty haul truck may be moved atstage 171 to the dump location and the material moving process may becontinued and stages 154-169 repeated.

Although described in the context of rope shovel 15, many of theconcepts disclosed herein are applicable to other similar machines andsystems. For example, FIG. 12 depicts an excavator 200 having multiplesystems and components that may cooperate to move material from a diglocation to a dump location. Excavator 200 may include a platform 201rotatably disposed on undercarriage 202. Undercarriage 202 may includeone or more ground engaging drive mechanism such as tracks 203.

Platform 201 may include a prime mover 204 operative to power animplement system 205 including a work implement or tool such as bucket206. Prime mover 204 may provide a rotational output to drive tracks203, thereby propelling the excavator 200. Prime mover 204 may alsoprovide power to other systems and components of the excavator 200.

The implement system 205 may include a boom 207, a connecting member orstick 208, and a work implement or tool. A first end of boom 207 may bepivotally connected to platform 201, and a second end of the boom may bepivotally connected to a first end of stick 208. The work implement ortool such as bucket 206 may be pivotally connected to a second end ofstick 208.

Rotation of platform 201 relative to undercarriage 202 may be effectedby a swing motor 210. Each linkage member may include and be operativelyconnected to one or more actuators such as hydraulic cylinders. Morespecifically, boom 207 may be propelled by one or more boom hydrauliccylinders 211 (only one being shown in FIG. 12). Stick 208 may bepropelled by a stick hydraulic cylinder 212. Rotation of the bucket 206relative to the stick 208 may be effected by a work implement hydrauliccylinder 213.

Each of the swing motor 210, boom hydraulic cylinders 211, stickhydraulic cylinder 212, and work implement hydraulic cylinder 213 may bedriven by a hydraulic system, generally indicated at 214, that may bepowered by the prime mover 204. Excavator 200 may include a controlsystem 215 and a controller 216 similar to those of rope shovel 15.

Excavator 200 may also include systems and sensors for efficientoperation of the machine. Such systems and sensors may be similar to orresult in similar measurements and functionality to the systems andsensors of rope shovel 15. As non-limiting examples, the mapping system70 of rope shovel 15 may be used with excavator 200 to generate anelectronic map of the work site 100 and store the electronic map withincontroller 216 in either rectangular or cylindrical coordinates.Re-positioning system 76 may also be used with excavator 200 to identifyinstances in which the excavator may not efficiently or safely load ahaul truck 80 that is positioned near the excavator. In addition, dumpheight positioning system 77 may be used with excavator 200 in instancesin which it is desired to control the height at which the bucket 206 isdumped. Finally, return-to-dig system 78 may be used with excavator 200in instances in which it is desired to utilize a return-to-dig processthat includes automated movement between a plurality of either diglocations or dump locations.

From the forgoing, it may be understood that each of the rope shovel 15and the excavator 200 includes a base rotatably mounted on anundercarriage having a ground engaging drive mechanism. Each of the ropeshovel 15 and the excavator 200 also includes an implement system orlinkage assembly mounted on the base. Each implement system includes aboom secured to the base although the boom 25 of the rope shovel isfixed while the boom 207 of the excavator is pivotably mounted to thebase or platform 201. Each of the rope shovel 15 and the excavator 200further includes a ground engaging work implement in the form of adipper 35 or bucket 206, respectively. The dipper 35 is fixed to dipperhandle 40 which is operatively connected to the boom 25 while the bucket206 is pivotably mounted on the stick 208.

INDUSTRIAL APPLICABILITY

The industrial applicability of the systems described herein will bereadily appreciated from the foregoing discussion. The presentdisclosure is applicable to many machines and tasks performed bymachines. Exemplary machines include rope shovels, hydraulic miningshovels, excavators, and backhoes.

A re-positioning system 76 may be used to identify instances in whichthe excavator may not efficiently or safely load a haul truck 80 that ispositioned near a machine such as rope shovel 15. A dump heightpositioning system 77 may be used when it is desired to control theheight at which the bucket 206 is dumped. A return-to-dig system 78 maybe used when it is desired to move a work implement such as dipper 35from a dump location to one or more dig locations in an automatedmanner.

It will be appreciated that the foregoing description provides examplesof the disclosed system and technique. However, it is contemplated thatother implementations of the disclosure may differ in detail from theforegoing examples. All references to the disclosure or examples thereofare intended to reference the particular example being discussed at thatpoint and are not intended to imply any limitation as to the scope ofthe disclosure more generally. All language of distinction anddisparagement with respect to certain features is intended to indicate alack of preference for those features, but not to exclude such from thescope of the disclosure entirely unless otherwise indicated.

Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context.

Accordingly, this disclosure includes all modifications and equivalentsof the subject matter recited in the claims appended hereto as permittedby applicable law. Moreover, any combination of the above-describedelements in all possible variations thereof is encompassed by thedisclosure unless otherwise indicated herein or otherwise clearlycontradicted by context.

1. A system for controlling movement of a work implement of a machinebetween a dump location and a plurality of dig locations, comprising: arotatable implement system at a work site having a linkage assemblyincluding the work implement; an implement system pose sensor forgenerating implement system pose signals indicative of a pose of theimplement system including a pose of the work implement; and acontroller configured to: store first dig signals from the implementsystem pose sensor indicative of a first dig location; store second digsignals from the implement system pose sensor indicative of a second diglocation, the second dig location being spaced from the first diglocation; store a dump location; generate command signals to move thework implement from the first dig location to the dump location;generate command signals to dump a load of material carried by the workimplement at the dump location; and generate command signals to move thework implement from the dump location to the second dig location.
 2. Thesystem of claim 1, wherein the controller is further configured to storethe first dig signals based upon positioning of the work implement atthe first dig location and actuation of an input device.
 3. The systemof claim 2, wherein the controller is further configured to store thesecond dig signals based upon positioning of the work implement at thesecond dig location and actuation of the input device.
 4. The system ofclaim 1, wherein the controller is further configured to storeautomatically the first dig signals upon entering a learning mode andthe work implement performing a predetermined digging operation.
 5. Thesystem of claim 4, wherein the controller is further configured to storeautomatically the second dig signals upon entering the learning mode andthe work implement performing a second predetermined digging operation.6. The system of claim 1, further including a rotatable base having thelinkage assembly mounted thereon, the linkage assembly including a boomoperatively connected to the base, a connecting member operativelyconnected to the boom and the work implement.
 7. The system of claim 6,wherein the implement system pose sensor includes sensors fordetermining a position of the linkage assembly.
 8. The system of claim6, wherein the boom is fixedly mounted to the base, and the workimplement is fixedly mounted on the connecting member.
 9. The system ofclaim 8, wherein the connecting member is slidably mounted on a saddleblock and the saddle block is pivotably mounted on the boom.
 10. Thesystem of claim 6, wherein the boom is pivotably mounted to the base,and the work implement is pivotably mounted on the connecting member.11. The system of claim 10, wherein the connecting member is pivotablymounted on the boom.
 12. The system of claim 1, wherein the controlleris further configured to store an electronic map including the implementsystem, the first dig location, the second dig location, and the dumplocation in cylindrical coordinates.
 13. The system of claim 1, furtherincluding a haul truck including a haul truck pose sensor for generatingtruck pose signals indicative of a pose of the haul truck, and thecontroller is further configured to determine the dump location basedupon the pose of the haul truck.
 14. The system of claim 1, wherein thecontroller is further configured to store a second dump location,generate command signals to move the work implement from the second diglocation to the second dump location, and generate command signals todump a load of material carried by the work implement at the second dumplocation.
 15. The system of claim 14, further including a second haultruck including a second haul truck pose sensor for generating secondtruck pose signals indicative of a pose of the second haul truck, andthe controller is further configured to determine the second dumpposition based upon the pose of the second haul truck.
 16. A controllerimplemented method for controlling movement of a work implement of amachine between a dump location and a plurality of dig locations, thework implement being operatively connected to a rotatable implementsystem having a linkage assembly, the method comprising: storing firstdig signals from an implement system pose sensor associated withimplement system the indicative of a first dig location; storing seconddig signals from the implement system pose sensor indicative of a seconddig location, the second dig location being spaced from the first diglocation; storing a dump location; generating command signals to movethe work implement from the first dig location to the dump location;generating command signals to dump a load of material carried by thework implement at the dump location; and generating command signals tomove the work implement from the dump location to the second diglocation.
 17. The method of claim 16, further including storing thefirst dig signals based upon positioning of the work implement at thefirst dig location and actuating an input device.
 18. The method ofclaim 16, further including storing automatically the first dig signalsupon entering a learning mode and the work implement performing apredetermined digging operation.
 19. The method of claim 16, furtherincluding storing a second dump location, generating command signals tomove the work implement from the second dig location to the second dumplocation, and generating command signals to dump a load of materialcarried by the work implement at the second dump location.
 20. A machinecomprising: a rotatable base; a linkage assembly, the linkage assemblyincluding a boom operatively connected to the base, a connecting memberoperatively connected to the boom, and a material moving work implementoperatively connected to the connecting member; an implement system posesensor for generating implement system pose signals indicative of a poseof the implement system including a pose of the work implement; and acontroller configured to: store first dig signals from the implementsystem pose sensor indicative of a first dig location; store second digsignals from the implement system pose sensor indicative of a second diglocation, the second dig location being spaced from the first diglocation; store a dump location; generate command signals to move thework implement from the first dig location to the dump location;generate command signals to dump a load of material carried by the workimplement at the dump location; and generate command signals to move thework implement from the dump location to the second dig location.